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S A F E T Y | Q U A L I T Y | P R O D U C T I V I T Y
A G r e a t A m e r i c a n S t e e l C o m p a n y
1
S A F E T Y | Q U A L I T Y | P R O D U C T I V I T Y
• NYSE: AKS
• Key values:
• Safety
• Quality
• Productivity
Max Eward
Safety Award Winner
This Is AK Steel
2
S A F E T Y | Q U A L I T Y | P R O D U C T I V I T Y
Company Heritage
First Heat: February 7, 1901
3
S A F E T Y | Q U A L I T Y | P R O D U C T I V I T Y
Facilities and Strategic Investments
Magnetation LLC
Iron Ore Pellet Plant AK Coal Resources
MN
MI
IN
KY
OH
PA
Dearborn Works
Spartan (Coating)
Double Eagle (EG)(1)
Delaco (Slitting) Mansfield Works
Coshocton Works
Zanesville Works
Ashland Works AK Tube LLC
Rockport Works
Middletown Works
West Chester, HQ
Mountain State Carbon
Butler Works
4
S A F E T Y | Q U A L I T Y | P R O D U C T I V I T Y
Stainless Steels Electrical Steels Carbon Steels
Products
5
6
Design Optimization Technologies in the Development of the Future
Steel Vehicle (FSV)
October 28th 2014
Nature’s Way to Mobility
2014 VR&D Design Optimization Users Conference
7
Presentation Topics
• Objectives
• Design Methodology W/
Focus on GENESIS
Topomentry Optimization
• Results
8
FSV Design Drivers
• Mass reduction
• Cost
• Total vehicle carbon footprint -
GHG Emissions; CO2e (kg)
– Material Manufacture
– Vehicle Manufacture
– Vehicle use phase (200,000 km)
– Vehicle recycling
9
Mass Target Setting
2470 mm
701 mm
839 mm 661 mm
2524 mm 595 mm
Body Structure
Mass (kg)
Powertrain
Mass (kg)
FSV 190 329
VW Polo 2010 231 233
FSV mass target
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FSV Steel Portfolio
denotes steel included in ULSAB-AVC
Mild 140/270 DP 350/600
BH 210/340
BH 260/370 SF 570/640 DP 700/1000
IF 260/410 MS 950/1200
IF 300/420
DP300/500
DP 500/800
HSLA 350/450 TRIP 450/800
MS 1250/1500
HSLA 490/600
denotes steel grades added for FSV
Mild 140/270 DP 350/600 TRIP 600/980
BH 210/340 TRIP 350/600 TWIP 500/980
BH 260/370 SF 570/640 HSLA 700/780
BH 280/400 HSLA 550/650 DP 700/1000
IF 260/410 TRIP 400/700 CP 800/1000
IF 300/420 SF 600/780 MS 950/1200
DP300/500 CP 500/800 CP 1000/1200
FB 330/450 DP 500/800 DP 1150/1270
HSLA 350/450 TRIP 450/800 MS 1150/1400
HSLA 420/500 CP 600/900 CP 1050/1470
FB 450/600 CP 750/900 HF 1050/1500
HSLA 490/600 MS 1250/1500
Expanded Range of Steel Grades
13
Global Reach Requirements
US NCAP EURO NCAP FMVSS 301 Rear ECE R32
IIHS Side FMVSS 214 Pole EURO NCAP Pole FMVSS 216a, IIHS Roof
RCAR/IIHS Low Speed
FSV Crash Safety Analyses
13
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• Fish-hook test
• Double lane change maneuver (ISO 3888-1)
• 3g pothole test
• 0.7g constant radius turn test
• 0.8g forward braking test
Durability and NVH Analysis
Durability, Ride and Handling Analyses
Static and Dynamic Stiffness Analyses
• Torsion Stiffness
• Bending Stiffness
• Global Modes
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15
T1
T6
T5
T4
T3
T2 Linear-Static
Topology
Optimisation
Gauge
Optimisation
Final Design
Confirmation
Phase1
Technology Assessment
Packaging
Non-Linear Dynamic
Optimization
(LF3G) Sub-System
Optimization
Detail Design
Styling &
aerodynamic
Design
Confirmation
Phase 2
Report
FSV Design Methodology
15
16
495.0
1065.0 850.0
300.0
328.0
780.0
2524.0
390.0
Minimum Vision & Obscuration Requirements
16° Approach Angle 25° Departure Angle13° Ramp Breakover Angle
Minimum Angles & Clearances
150 mm Ground Clearance
FSV BEV Packaging
16
17
T1 T1
T6
T5
T4
T3
T2 Linear-Static
Topology
Optimisation
Gauge
Optimisation
Final Design
Confirmation
Phase1
Technology Assessment
Packaging
Non-Linear Dynamic
Topology Optimisation
(LF3G) Sub-System
3G Optimisation
Detail Design
Styling &
Aerodynamic
Design
Confirmation
Phase 2
Report
T1
Aerodynamics & Styling
17
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Styling & CFD
Coefficient of Drag (CD) Target: 0.25
T1
First styling theme
Latest Styling CD: 0.24
18
19
T1
T6
T5
T4
T3
T2 Linear-Static
Topology
Optimisation
Gauge
Optimisation
Final Design
Confirmation
Phase1
Technology Assessment
Packaging
Non-Linear Dynamic
Optimization
(LF3G) Sub-System
Optimization
Detail Design
Styling &
Aerodynamic
Design
Confirmation
Phase 2
Report
Linear-Static Topology Optimization (GENESIS)
T2
19
20
T1
T6
T5
T4
T3
T2 Linear-Static
Topology
Optimisation
Gauge
Optimisation
Final Design
Confirmation
Phase1
Technology Assessment
Packaging
Non-Linear Dynamic
Optimization
(LF3G) Sub-System
Optimization
Detail Design
Styling &
aerodynamic
Design
Confirmation
Phase 2
Report
T2
Topology Optimization Load Cases (GENESIS)
20
21
Multiple Vehicle Design Spaces:
Battery Floor
Battery Bulkhead
Seat Cross-member
BIW (Body-In-White)
Optimization Design Space
23
Battery Bulkhead
Seat Cross-members
Vehicle
Front
Vehicle
Rear
Interpreting Results Sub Design Spaces
25
Topology Optimization Mass Fractions
30% Mass Fraction 20% Mass Fraction 10% Mass Fraction
Interpreted CAD
Geometry
Creation of Sheet Structure
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• Topology optimization drives the material of structure to where it is most effective.
• Allow Topology Load Path Optimisation to influence locations and shape of components based on Packaging.
• Topology Optimisation is interpreted by engineering judgment.
Linear-Static Topology Optimisation Results
27
T1
T6
T5
T4
T3
T2 Linear-Static
Topology
Optimization
Gauge
Optimization
Final Design
Confirmation
Phase1
Technology Assessment
Packaging
Non-Linear Dynamic
Topology Optimization
(LF3G) Sub-System
Topography
Optimization
Detail Design
Styling &
aerodynamic
Design
Confirmation
Phase 2
Report
LF3G Load Path and 3G Optimisation
T3
30
T3
T1
T6
T5
T4
T2 Linear-Static
Topology
Optimisation
Gauge
Optimisation
Final Design
Confirmation
Phase1
Technology Assessment
Packaging
Non-Linear Dynamic
Topology Optimisation
(LF3G) Sub-System
Topography
Optimisation
Detail Design
Styling &
aerodynamic
Design
Confirmation
Phase 2
Report
Sub-Systems 3G Optimisation
T4
31 31
Selected Sub-Systems
• Front Rail
• Shot Gun
• Rocker
• B-Pillar
• Rear Rail
• Roof Rail
• Tunnel Reinforcement
T4 Load Path Mapping
32
Move together for flat
mating condition
Independent Control Points
Rocker otr
Rocker reinf
Floor side inr
Hold seal flange
Design Space (common)
Body Structure – Sub-System 3G Optimisation
S2 S1
S3 S4
S5 T4
33
Stamping
AHSS
Roll-forming
AHSS
Hydroforming
AHSS
Extrusion
Aluminum
Body Structure Sub-System – Rocker Solutions
34
Laser
Welded
Blanks
Tailor
Rolled
Blanks
Standard
Blanks
Conventional
Stamping
Roll
Forming Hydroforming
Hot
Stamping
Body Structure Sub-System – Rocker Solutions
ST
ST LWB
ST TRB HST TRB
HST LWB
HST
RF TRB
RF LWB
RF
HF TRB
HF LWB
HF
35
T1
T6
T5
T4
T3
T2 Linear-Static
Topology
Optimization
Gauge
Optimization
Final Design
Confirmation
Phase1
Technology Assessment
Packaging
Non-Linear Dynamic
Topology Optimization
(LF3G) Sub-System
Topography
Optimization
Detail Design
Styling &
aerodynamic
Design
Confirmation
Phase 2
Report
T4
FSV Task 4 Decisions
36
Baseline OPT Parts Mass = 213.7 kg
Optimized Design 336 = 190.6 kg
Total Mass Savings = 23.1 kg (10.8%)
Baseline BIW Mass = 203.7 kg
Optimized Design 336 BIW = 188.0 kg
BIW Mass Savings = 15.7 kg (8.4%)
Best Design: #336
36
Final Grade & Gauge (2G) Full System Optimisation
38
T1
T6
T5
T4
T3
T2 Linear-Static
Topology
Optimisation
Gauge
Optimisation
Final Design
Confirmation
Phase1
Technology Assessment
Packaging
Non-Linear Dynamic
Topology Optimisation
(LF3G) Sub-System
Topography
Optimisation
Detail Design
Styling &
Aerodynamic
Design
Confirmation
Phase 2
Report
T2
#1 – State of the Future Design Innovations
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Body Structure
FSV-1 BEV Mass (kg)
Benchmark 290
Target 190
Achieved 188
#2 – 35% Mass Savings
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BEV – 188 kg
PHEV20 – 175 kg
FSV-2: PHEV40 and
FCEV – 201 kg
40
#3 – 97% HSS and AHSS
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Body Structure
FSV-1 BEV Mass (kg)
Benchmark 290
Target 190
Achieved 188
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#4 – Nearly 50% GigaPascal Steels
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Body Structure
FSV-1 BEV Mass (kg)
Benchmark 290
Target 190
Achieved 188
43
#6 – Reduces Life Cycle Emissions
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Vehicle/Powertrain
Material & Recycling (kg CO2e)
Use Phase (kg CO2e)
Total Life Cycle (kg CO2e)
Benchmark V ICEg 1,479 32,655 34,134
FSV BEV USA grid 1,328 13,844 15,172
FSV BEV Europe grid
1,328 9,670 10,998
FSV vs. Benchmark – USA Grid - 56% CO2e reduction
FSV vs. Benchmark – Europe Grid - 68% CO2e reduction
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#7 – No Cost Penalty
Cost
(US$)
Body Structure Manufacturing Costs $775
Body Structure Assembly Costs $340
Total Body Structure Manufacturing & Assembly $1,115
44